Air handler heat kit installation and mounting

ABSTRACT

A heating arrangement is provided for use in an air handling unit. The heating arrangement includes at least one heating device to be disposed in the airflow of an air handling unit. A base is configured to support the at least one heating device and a first guide member to be mounted on a structural component inside the air handling unit. A second guide member is mounted on the base, the second guide member being configured to slidably engage the first guide member. Sliding engagement of the first guide member and the second guide member positions the at least one heating device to an installed position inside the air handling unit.

FIELD OF THE INVENTION

The present invention is directed to a heat kit installation, and more particularly, is directed to a heat kit installation mounting device for use with an air handling unit.

BACKGROUND OF THE INVENTION

Air handling units (AHUs) are one of several components in cooling and heating systems. They are an important component as the AHU houses a number of components used in the system to provide forced air for climate control in a particular structure. AHU components typically include motors, heating/cooling coils, and blowers as well as the required interface connections to effect such climate control.

As discussed above, an AHU compartment or blower compartment includes adjacent walls partially surrounding a blower with support structure extending transversely to the blower. Transverse members extending between support structures structurally secure the blower against an aperture formed in the wall so that during operation of the blower, air is propelled from the blower compartment for circulation of the air to the structure. Some AHUs are provided with what is commonly referred to as an electric heat kit or heat kit. A heat kit typically includes electric resistance heating elements and associated components required for operation. The electric resistance heating elements and associated components are typically secured to a single support structure within the AHU.

The heat kit is typically installed into the AHU so that the electric resistance heating elements are disposed adjacent to a blower. The electric resistance heating elements heat the air that is circulated through a structure by the blower. To install a heat kit inside the AHU, the heat kit is typically directed inside a compartment containing the blower. The portion of the heat kit containing the electric resistance heating elements is then inserted through an opening in a wall separating the compartment containing the blower from an adjacent compartment downstream from the blower compartment. The clearance between the opening and the electric resistance heating elements is minimal, since it is desirable to maximize the surface area of the electric resistance heating elements with respect to the cross sectional surface area of the adjacent compartment to maximize the effectiveness of the electric resistance heating elements. However, the minimal clearance between the compartmental wall opening and the electric resistance heating elements results in a difficult installation of the heat kit, which is further complicated due to the susceptibility to damage to the electric resistance heating elements. The installation is yet further complicated when performed as a retrofit to an operational AHU, in which the blower can be positioned in non-ergonomic orientations that are poorly lit.

Some heat kits include an aperture in a distal portion of a blower compartment of an AHU that engages a rod secured to the heat kit when the heat kit is properly installed to secure the heat kit in position. However, this construction does nothing to simplify the installation of the heat kit, as the electric heating elements must still be painstakingly guided through the opening in the compartmental wall of the AHU.

What is needed is a heat kit mounting device that greatly simplifies the installation of a heat kit inside an AHU, while providing a reduction in both installation time and significantly reducing the opportunity to damage the electric resistance heating elements during installation.

SUMMARY OF THE INVENTION

The present invention relates to a heating arrangement for use in an air handling unit including at least one heating device to be disposed in the airflow of an air handling unit. A base is configured to support the at least one heating device and a first guide member is to be mounted on a structural component inside the air handling unit. A second guide member is mounted on the base, the second guide member being configured to engage the first guide member. Engagement of the first guide member and the second guide member positions the at least one heating device to an installed position inside the air handling unit.

The present invention further relates to a method of installing a heating arrangement in an air handling unit. The steps include providing at least one heating device to heat an airflow of an air handling unit and providing a base configured to support the at least one heating device, the base including a first guide member. The method further includes mounting a second guide member on a structural component inside the air handling unit, and aligning the first guide member with the second guide member to engage the second guide member. The method further includes directing the first guide member into engagement with the second guide member to position the at least one heating device in an installed position inside the air handling unit.

An advantage of the present invention is that it is inexpensive to manufacture.

A further advantage of the present invention is that it requires few parts.

A still further advantage of the present invention is that it reduces the time required to install a heat kit inside an AHU.

An additional advantage of the present invention is that it simplifies installation of a heat kit inside an AHU.

A further advantage of the present invention is that it reduces the opportunity to damage the electric resistance heating elements during installation of a heat kit inside an AHU.

Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an enlarged, partial perspective view of a AHU blower compartment including a guide of the present invention.

FIGS. 2 and 3 are opposed perspective views of a heat kit of the present invention.

FIGS. 4-6 are perspective views of embodiments of a heat kit of the present invention.

FIG. 7 is an enlarged, partial perspective view of a partially installed heat kit of the present invention.

FIG. 8 is an enlarged, partial perspective view of embodiments of a fully installed heat kit of the present invention.

FIG. 9 is a partial end view of an alternate embodiment of a heat kit bracket engaged with a guide of the present invention.

FIG. 10 is a partial end view of a further alternate embodiment of a heat kit bracket engaged with a guide of the present invention.

Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are typically not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates one embodiment of a guide 30 in an AHU compartment 10. As discussed above, the AHU compartment or blower compartment 10 includes adjacent walls 15, 16, 18 partially surrounding a blower 12 with support structures 20, 22 extending transversely to the blower 12. Transverse members 24, 26 extending between support structures 20, 22 structurally secure the blower 12 within the blower compartment 10 so that during operation of the blower 12, air is propelled from the blower compartment 10 for circulation of the air to the structure. Guide 30 facilitates easy installation of a heat kit 52 (FIG. 2) inside the blower compartment 10, wherein a heater 62 of the heat kit 52 is directed through a narrow opening 28 in the blower compartment without damaging the heater 62 of the heat kit 52.

Further referring to FIG. 1, guide 30 is supported by support members 20, 22, such as angle rail members, and may additionally include a tab 46 extending from an end 42 of the guide 30 that is received in a slot 45 formed in a panel 14 of the AHU compartment that is secured to support member 20. Guide 30 includes a base 32 having opposed sides 34, 36, with retainers 35, 37 extending from the respective sides 34, 36. Collectively, retainer 35 and retainer 37 each define a channel 38 with the base 32 to receive a portion of a heat kit 52, such as a bracket 78 (see FIGS. 2, 3) for guiding the heat kit 52 into an installed position (see FIG. 8) without damaging the heat kit 52. Moreover, a projection 44 is preferably disposed adjacent to both the end 40 and the channel 38 of guide 30, as will be further discussed in detail below. Preferably, tab 46 extends from end 42 of the guide 30 for insertion into slot 45 in the panel 14 to secure the guide 30 to the support structure inside the AHU blower compartment. It is also preferable that a tab 48 extends from end 40 at an angle with respect to the base 32 to abut the support structure 20 upon installation of the guide 30 inside the AHU blower compartment 10. A fastener 50, such as a screw or bolt, is actuated to secure the guide 30 to the support structure 20.

It is appreciated that in FIG. 1 the guide 30 is shown having a unitary construction including a pair of channels for receiving corresponding structure of the heat kit 52. However, the guide 30 can be constructed of two or more pieces, and can be any suitable construction that slidably engages the heat kit 52 so that the heat kit 52 is not damaged during installation inside the AHU blower compartment 10, irrespective the orientation of the heat kit 52.

Both the opening 28 and slot 45 formed in the panel 14 of the AHU blower compartment 10, as well as the aperture for securing tab 48 of guide 30 to the support member 22 if desired, can be formed during manufacture of the AHU blower compartment 10. A plate (not shown) can then be installed over opening 28 if the AHU as manufactured is not to include the heat kit. Alternately, a template (not shown) provided with each heat kit can be used to locate and subsequently form the opening 28 and slot 45 in panel 14 of the AHU blower compartment 10.

Referring to FIGS. 1-6, heat kit 52 includes a base 54 having adjacent base portions 56, 58 preferably maintained perpendicular to each other for securing respective components 70, 68 thereto. An end of base portion 56 includes a retainer 60 for abutting the support structure 20 when the heat kit 52 is in an installed position (see FIG. 8). The retainer 60 includes a gap 61 so that retainer 60 does not interfere with the tab 48 of the guide 30. Components 70, 68 can include any combination of limit switches, control devices, such as relays or sequencers, circuit breakers, or the like required for operation of the heat kit 52. Components 70, 68 are electrically connected by an electrical connection 72, as required. Further, one of the components 70, 68 include a wiring harness 74 and connector 76 to connect with an electrical power source (not shown). Preferably, heater 62 extends substantially perpendicular from base portion 58 so that when the heater 62 is installed in the AHU compartment 10, heater 62 extends through the opening 28 of the AHU compartment and is in fluid communication with the air provided by the blower 12 for providing heated air to the structure. Heater 62 typically includes a plurality of supports 66 secured to the base portion 58, the supports 66 supporting electric resistance coils 64 that become heated when electrical current is applied to the coils 64.

To secure the heat kit 52 to the guide 30, a bracket 78 is secured to the bottom surface of the base portion 56 adjacent to the juncture of base portions 56, 58. Bracket 78 includes a base 80 having opposed legs 82 extending substantially perpendicular to the juncture of base portions 56, 58. Each leg 82 has a leg portion 84 extending away from the base 80, such as perpendicular from the base 80, and a flange 86 extending from leg portion 84 away from the base 80. Flanges 86 preferably are substantially parallel with the base portion 56. The ends of the flanges 86 adjacent to the juncture between the base portions 56, 58 each include a chamfer 88 to more easily facilitate the engagement of the flange 86 with the guide 30. To install the heat kit 52, the chamfered end 88 of the flanges 86 are directed toward and between the oversized projections 44, which greatly assists in aligning the flanges 86 with the channels 38 of the guide 30. The projections 44 may be parallel to each other or non-parallel to each other, such as defining a V-shape, to provide a “funnel effect” to further assist in bringing the flanges 86 into alignment with the channels 38. Once the flanges 86 are disposed between the projections 44 with each chamfered end 88 of a flange 86 adjacent to a corresponding channel 38, the orientation of the base portion 56 must only be slightly pivoted about an axis 89 defined by the chamfered ends 88 to sufficiently align the flange 86 with the corresponding channels 38 to permit insertion of the flanges 86 inside the channels 38. Once the flange 86 insertion begins to occur, the heat kit 52 is properly aligned so that the heater 62 can be directed through the opening 28 until base portion 58 of the heat kit 52 abuts the panel 14 of the AHU compartment, the base portion 58 completely covering and overlapping the opening 28 as shown in FIG. 8.

FIG. 7 shows the heat kit 52 being partially installed after the flanges 86 and the channels 38 have been partially engaged, while FIG. 8 shows the heat kit 52 in a fully installed position. To secure the heat kit 52 in its installed position, fasteners (not shown) can be installed through either or both of the base portions 56, 58 of the base 54 of the heat kit 52 and supporting structure 20, 22 or panel 14 of the AHU compartment wall.

In an alternate construction to bracket 78, referring to FIG. 4, a U-shaped rod 90 having opposed legs 92 separated by a web 94 is secured at a predetermined spacing from the bottom of base portion 56 for engaging guide 30. Each end of the legs 92 extends through an aperture 98 formed in retainer 60. Preferably, a standoff 100, or two or more of standoffs 100, is interposed between the web 94 and the base portion 56 to secure the web 94. To install the heat kit 52 in the AHU compartment 10, the junctures of the legs 92 and web 94 are directed toward and between the oversized projections 44, which greatly assists in aligning the legs 92 with the channels 38 of the guide 30. Once the junctures of the legs 92 and web 94 are disposed between the projections 44 with each juncture of the legs 92 and web 94 adjacent to a corresponding channel 38, the orientation of the base portion 56 must only be slightly pivoted about the web 90 to sufficiently align the legs 92 with the corresponding channels 38 to permit insertion of the legs 92 inside the channels 38. Once the leg 92 insertions begin to occur, the heat kit 52 is properly aligned so that the heater 62 can be directed through the opening 28 until base portion 58 of the heat kit 52 abuts the panel 14 of the AHU compartment 10.

Referring to FIG. 5, a pair of rod members 102 is used to guide heat kit 52 inside the AHU compartment 10. Each rod member 102 includes a substantially straight section 110 that extends to a transition portion 106 having an end 104 that is inserted into an aperture 98 formed in the retainer 60. Opposite the transition portion 106, the substantially straight section 110 extends to a transition portion 108 that is secured to the base portion 56 by methods known in the art, including adhesives, welding, or insertion into a recess formed in the base portion 56. To install the heat kit 52 in the AHU compartment, the junctures of the transition portions 108 and rod members 102 are directed toward and between the oversized projections 44, which greatly assists in aligning the straight portions 110 with the channels 38 of the guide 30. Once the junctures of the transition portions 108 and straight portions 110 are disposed between the projections 44 with each juncture of the transition portions 108 and straight portions 110 adjacent to a corresponding channel 38, the orientation of the base portion 56 must only be slightly pivoted about an axis 111. Pivoting about axis 111, which is defined by the juncture of the transition portions 108 and straight portions 110, sufficiently aligns the straight portions 110 with the corresponding channels 38 to permit insertion of the straight portions 110 inside the channels 38. Once the straight portion 110 insertions begins to occur, the heat kit 52 is properly aligned so that the heater 62 can be directed through the opening 28 until base portion 58 of the heat kit 52 abuts the panel 14 of the AHU compartment, the base portion 58 completely covering and overlapping the opening 28 as shown in FIG. 8.

Referring to FIG. 6, another embodiment of the heat kit 52 includes a pair of opposed legs 112 extending from the bottom of base portion 56. Each leg 112 includes a leg portion 114 that extends away from the base portion 56, and flange 116 that extends from the leg portion 114 away from base portion 56. The legs 112 provide a unitary base 54 construction. Each flange 116 is configured to engage a corresponding channel 38 to secure the heat kit 52 to the guide 30, the flanges 116 preferably including a chamfer 118 adjacent the juncture of base portions 56, 58 to further facilitate engagement with the channel 38 in a manner previously discussed.

Those skilled in the art can appreciate that although the guide 30 is shown as a component that is installed in the AHU compartment, the guide can be incorporated into the existing support structure 20, 22 or transverse members 24, 26, if desired. Further, although the guide 30 as shown requires the heat kit to be inserted inside the AHU compartment, the guide can be extended outside the AHU compartment to permit the heat kit to engage the guide exterior of the AHU compartment, the guide being usable to guide the heat kit to its installed position. The extended portion of the guide could be removable if desired.

It is to be understood that base 54 and base portion 56 can have unequal widths. Further, while retainers 35, 37 are shown to define channels 38 on guide 30 that face each other (i.e., FIG. 1), as shown in FIG. 9, the channel arrangement can also face away from each other. For example, guide 130 includes a base 132 having opposed legs 134. Each leg 134 has a leg portion 136 extending away from the base 132, such as perpendicular to the base 132 and a flange 138 extending from leg portion 136 away from base 132. Flanges 138 preferably are substantially parallel with the base 132. Bracket 178, which is otherwise similar to bracket 78, includes flanges 186 that differ from flanges 86 in that flanges 186 extend toward each other. Collectively, each flange 186, leg portion 84 and base 80 defines a channel 188. Each flange 138 of the bracket 130 slidably engages a corresponding channel 188 to secure the base portion 56 of the heat kit 52 to the guide 130.

In a further alternate guide construction as shown in FIG. 10, guide 230 includes a base 232 having a leg 234 extending away from the base 232. Leg 234 terminates at a cap 236 having flange portions 238 extending away from leg 234. Each flange portion 238 slidably engages a corresponding channel 188 to secure the base portion 56 of the heat kit 52 to the guide 230.

While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. 

1. A heating arrangement for use in an air handling unit comprising: at least one heating device to be disposed in the airflow of an air handling unit; a base configured to support the at least one heating device; a first guide member to be mounted on a structural component inside the air handling unit; a second guide member mounted on the base, the second guide member being configured to engage the first guide member; and wherein engagement of the first guide member and the second guide member positions the at least one heating device to an installed position inside the air handling unit.
 2. The heating arrangement of claim 1 wherein the first guide member has at least one channel.
 3. The heating arrangement of claim 1 wherein the first guide member has at least one projection.
 4. The heating arrangement of claim 3 wherein the first guide member has at least one channel, the at least one channel being adjacent to the at least one projection.
 5. The heating arrangement of claim 4 wherein the at least one projection has a pair of substantially parallel projections.
 6. The heating arrangement of claim 4 wherein the at least one projection has a pair of projections disposed in a V-shape.
 7. The heating arrangement of claim 2 wherein the second guide member has at least one flange for engaging the at least one channel.
 8. The heating arrangement of claim 2 wherein the second guide member has at least one rod member for engaging the at least one channel.
 9. The heating arrangement of claim 7 wherein the at least one flange is unitary with the base.
 10. The heating arrangement of claim 7 wherein the at least one flange has a chamfered edge for engaging the at least one channel.
 11. The heating arrangement of claim 7 wherein the at least one flange includes a pair of inwardly directed flanges.
 12. The heating arrangement of claim 7 wherein the at least one flange includes a pair of outwardly directed flanges.
 13. The heating arrangement of claim 1 wherein the second guide member has at least one projection.
 14. The heating arrangement of claim 1 wherein engagement of the first and second guide member is sliding engagement.
 15. A method of installing a heating arrangement in an air handling unit, the steps comprising: providing at least one heating device to heat an airflow of an air handling unit; providing a base configured to support the at least one heating device, the base including a first guide member; mounting a second guide member on a structural component inside the air handling unit; aligning the first guide member with the second guide member to engage the second guide member; and directing the first guide member into engagement with the second guide member to position the at least one heating device in an installed position inside the air handling unit.
 16. The method of claim 15 wherein the second guide member includes at least one channel.
 17. The method of claim 15 wherein the second guide member includes at least one projection.
 18. The method of claim 17 wherein the second guide member has at least one channel, and the step of aligning the first guide member with the second guide member includes placing the at least one channel adjacent the at least one projection.
 19. The method of claim 18 wherein the at least one projection has a pair of substantially parallel projections.
 20. The method of claim 18 wherein the at least one projection has a pair of projections disposed in a V-shape.
 21. The method of claim 16 wherein the first guide member includes at least one flange for engaging the at least one channel.
 22. The method of claim 16 wherein the first guide member includes at least one rod member for engaging the at least one channel.
 23. The method of claim 21 wherein the at least one flange is unitary with the base.
 24. The method of claim 21 wherein the at least one flange has a pair of inwardly directed flanges.
 25. The method of claim 21 wherein the at least one flange has a pair of outwardly directed flanges.
 26. The method of claim 22 wherein the step of directing includes directing the first guide member into engagement with the second guide member exterior of the air handling unit.
 27. The method of claim 15 wherein the first guide member includes at least one channel.
 28. The method of claim 15 wherein the step of directing includes directing the first guide member into sliding engagement with the second guide member. 